GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01EU7CE02
      Text in Illustration
      *1 Generator Drive End Frame Bearing

      Using SST and a press, press in a new generator drive end frame bearing.

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01EZ3QE05
      Text in Illustration
      *a Tab
      *b Cutout

      Fit the tabs on the bearing retainer plate into the cutouts on the generator drive end frame assembly to install the bearing retainer plate.

    3. Install the 4 screws

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Place the generator drive end frame assembly on the generator pulley with clutch.

    2. Install the generator rotor assembly to the generator drive end frame assembly.

  3. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Temporarily install the generator pulley with clutch onto the rotor shaft.

    2. Hold the generator drive end frame assembly in a vise between aluminum plates.

    3. A01EWJ9E03
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

      Confirm SST (A) and (B) shown in the illustration.

      SST
      09820-63021
    4. A01ETYQE02
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

      Place the rotor shaft end into SST (A).

    5. A01EXK5E02
      Text in Illustration
      *1 Generator Pulley with Clutch
      *2 SST (A)
      *3 SST (B)

      Fit SST (B) to the generator pulley with clutch.

    6. A01EUGGE12
      Text in Illustration
      *1 SST (B)
      *2 SST (A)
      *a

      Fulcrum Length

      255 mm (10.00 in.)

      Tighten the generator pulley with clutch by turning SST (B) in the direction shown in the illustration.

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 255 mm (10.00 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench

      • Check that the generator drive end frame assembly is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

    7. Remove SST from the generator assembly.

    8. Check that the generator pulley with clutch rotates smoothly.

    9. Install a new generator pulley cap to the generator pulley with clutch.

  4. INSTALL GENERATOR COIL ASSEMBLY


    1. Place a new generator washer on the generator rotor assembly.

    2. A01EVT0E05

      Using SST and a press, press in the generator coil assembly to the generator drive end frame assembly.

      SST
      09612-70100   ( 09612-07240 )

    3. Install the cord clip with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    4. Install the 4 bolts.

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01EZ1GE18
      Text in Illustration
      *1 Pin

      While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the generator brush holder assembly hole .

    2. A01ETH7

      Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }
    3. A01EY8SE04
      Text in Illustration
      *1 Pin
      *a Pull out

      Pull out the pin from the generator brush holder assembly.

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01EWOO

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Pay attention to installation direction of the generator terminal insulator.

  7. INSTALL GENERATOR REAR END COVER


    1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.

      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }